Rapid ceramic matrix composite production method

Abstract

A method of producing a ceramic matrix composite component for use in a gas turbine engine comprising forming a ceramic matrix composite component, assembling the preform in a tool, loading the tool into a furnace and infiltrating the preform. Infiltrating the preform may include the methods of CVI, CVD, slurry infiltration, and melt infiltration.

What is claimed is: 
     
       1. A method of producing a ceramic matrix composite comprising a) applying a fiber interface coating to fibers b) coating the fibers via chemical vapor infiltration to create a coated fiber composite, and c) infiltrating the coated fiber composite with a molten material via melt infiltration, wherein the fibers are not removed from a tool in a furnace between steps (a), (b), and (c), and wherein the tool comprises a tool inlet port configured to accommodate the intake of gas and of molten material, and a tool exhaust port, wherein the tool exhaust port includes an outlet with a material in the outlet, the material permitting gas flow therethrough and creating a seal by blocking particulate and/or reacting with the molten material. 
     
     
       2. The method of  claim 1 , wherein the chemical vapor infiltration is a forced flow processes. 
     
     
       3. The method of  claim 1 , wherein the chemical vapor infiltration process applies a coating using a pressure gradient of about 0.005 to about 1.0 atm. 
     
     
       4. The method of  claim 3 , wherein the coating is carbon, boron nitride, or silicon doped boron nitride. 
     
     
       5. The method of  claim 1 , wherein the chemical vapor infiltration applies silicon carbide, silicon nitride carbide, boron carbide, or carbon as a coating. 
     
     
       6. The method of  claim 1 , wherein the fiber interface coating is about 0.1 μm to about 15.0 μm. 
     
     
       7. The method of  claim 1 , wherein the tool is a multi-piece tool. 
     
     
       8. The method of  claim 1 , wherein the tool is a single piece tool. 
     
     
       9. The method of  claim 1 , wherein the molten material comprises an alloy. 
     
     
       10. The method of  claim 1 , wherein the molten material comprises silicon carbide, carbon, or a ceramic particulate. 
     
     
       11. The method of  claim 1 , wherein the composite is multi-layered. 
     
     
       12. The method of  claim 1 , wherein at least one layer comprises at least one of a carbide, a nitride, a boride, or carbon. 
     
     
       13. The method of  claim 1 , wherein at least one layer is silicon carbide. 
     
     
       14. The method of  claim 1 , wherein at least one layer is boron nitride. 
     
     
       15. A method of producing a ceramic matrix composite component for use in a gas turbine engine comprising:
 preforming a ceramic composite component preform by laying up ceramic fibers, assembling the ceramic composite component preform in a tool to create a three dimensional component, 
 loading the tool into a furnace, 
 infiltrating the ceramic composite component preform with boron nitride to coat the ceramic fibers, 
 infiltrating the ceramic composite component preform including the coated ceramic fibers via slurry infiltration, 
 infiltrating the ceramic composite component preform via melt infiltration with silicon metal or silicon alloy to form a ceramic matrix composite component, and 
 removing the tool from the ceramic matrix composite component, wherein the tool comprises a tool inlet port configured to accommodate the intake of gas and molten material, and a tool exhaust port, wherein the tool exhaust port includes an outlet with a material in the outlet, the material permitting gas flow therethrough. 
 
     
     
       16. The method of  claim 15 , wherein the ceramic composite component matrix preform is not removed from the tool during any infiltration. 
     
     
       17. The method of  claim 1 , wherein the tool has a lower coefficient of thermal expansion than the ceramic matrix composite. 
     
     
       18. The method of  claim 15 , wherein the material further creates a seal by blocking particulate and/or reacting with the molten material. 
     
     
       19. A method of producing a ceramic matrix composite comprising a) applying a fiber interface coating to fibers, b) coating the fibers via chemical vapor infiltration to create a coated fiber composite, and c) infiltrating the coated fiber composite with a molten material via melt infiltration, wherein the fibers are not removed from a tool in a furnace between steps (a), (b), and (c), and wherein the tool comprises a tool inlet port configured to accommodate the intake of gas and of molten material, and a tool exhaust port, wherein the tool exhaust port includes an outlet with a material in the outlet, the material permitting gas flow therethrough.